1. Horizontal Joint Gasket Failure Feedwater Systems Reliability Users Group Presenter: Kurt J Weis Rotating Equipment Repair, Inc.

2. Finite Element Analysis To resolve split case gasket failure Ingersoll Rand 12 Stage Split Case Pump 4X10-12DAH-E

3. Equipment Analyzed Ingersoll Rand 12 stage spilt case pump 4X10-12DAH-E 3000-3600psi operating range

4. Failure Mode: Internal Recirculation MTBF: <2500 hours

5. Previous Repair Solutions Different Gasket materials Increased Stud Preload (Use of “Super Studs”) Beveled or Tapered Joint

6. Analyzing the Failure Mode Gasket has minimal contact pressure between stages causing internal recirculation Contact pressure can be analyzed with FEA Accurate full casing model required to perform FEA

7. Creating Accurate Model White Light Scanner/Digitizer gathered 3D point cloud data needed to create a model.

8. Creating Model Using point cloud data, a Pro-E solid model-assembly was created.

9. Model Constraints CA6NM Material, a 400 series stainless steel cast material Feet restricted to horizontal movement only Internal pressures

10. Pressure Distribution

11. Analysis 1 Standard Casing, 75% stud preload, (original design) to establish baseline.

12. Analysis 2 Standard Casing, 112% stud preload

13. Beveled Casing, Analysis 3

14. Analysis 3 Beveled or Tapered Casing, 75% Stud Preload

15. Additional Row of Studs, Analysis 4

16. Analysis 4 Additional Row of studs, 75% Stud Preload

17. Analysis 5 Additional Row of studs and beveled joint, 75% Stud Preload

18. The final design choice: Additional row of studs with no joint bevel

19. Manufacturing

21. Completed Product

24. Results Three pumps rebuilt with this modification. No pumps have been removed from service yet. First installed pump has over 17000 hours on it, with no degradation in performance.

25. Reverse Engineering The same technology can be used for reverse engineering impellers

26. Example Circulating Water Pump Impeller Failure

27. Large Horizontal Circ Pump Impeller Impeller was scanned and modeled using same technologies

28. Pattern Fabrication using Model

29. Casting Poured with CA6NM

30. Machining

31. Old to New Impeller Comparison

33. Deviation Report

34. Completed Product

36. Completed Product Installed

37. Questions?